Dimensionally stable product and process of fabricating a dimensionally stable product

ABSTRACT

Described herein is a dimensionally stable flooring product comprising a first layer having an upper surface opposite a lower surface and a first thickness ranging from about 70 mils to about 150 mils, a second layer having an upper surface opposite a lower surface and a second thickness ranging from about 14 mils to about 60 mils, the second layer further comprising a non-woven intermediate layer positioned between the upper surface and the lower surface of the second layer; and a bottom layer having an upper surface opposite a lower surface, wherein the upper surface of the second layer is heat-adhered to the lower surface of the first layer and the upper surface of the bottom layer is coupled to the lower surface of the first layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 13/225,777 filed on Sep. 6, 2011. The disclosure of the above application is incorporated herein by reference.

FIELD OF THE INVETNION

The present invention relates to dual layer products, and processes for fabricating dual layer products. More specifically, the present invention relates to heat-adhered dimensionally stable products and processes of fabricating such products.

BACKGROUND

Laminated products, such as vinyl flooring laminate, are used in various facilities and applications where dimensional stability or buckling resistance are desired. Laminated products are also used in ceilings, walls, table-tops, counter-tops, cabinets, or other suitable applications.

Some vinyl laminated products suffer from a drawback of being rough, having inconsistent surfaces, and/or being further misaligned over time. For example, some laminated. products are further misaligned though dimensional instability between layers of the laminated products. In these products, when one or more than one layer is subjected to extreme temperatures, the expansion and/or contraction of such layers results in relative movement of the layers or portions of the layers. Such relative movement can result in delamination, separation of the layers, bubbles, buckling, cracking, curling, other undesirable consequences, or combinations thereof. In one known product, such dimensional instability results in end gap openings of flooring of up to between about 48 mils and about 96 mils on a four foot plank.

Glass sheet products have better dimensional stability than known vinyl laminated products. However, glass sheet products are too flexible for certain applications, may undesirably buckle, may be undesirably semi-translucent or semi-transparent (for example, when married to a rigid dark colored backing), may not bridge subfloor irregularities, and/or may lack desired adhesion between separate layers.

Such drawbacks of vinyl laminated products and glass sheet products can be intensified when flexible layers are adhered to rigid products.

A dimensionally stable product having a flexible layer adhered to a rigid layer, and a process of fabricating such a product that do not suffer from e of the above drawbacks would be desirable in the art.

BRIEF SUMMARY

The present invention is directed to a laminate flooring product comprising: a first layer having an upper surface opposite a lower surface and a first thickness ranging from about 70 mils to about 150 mils as measured from the upper surface to the lower surface of the first layer; and a second layer having an upper surface opposite a lower surface and a second thickness ranging from about 14 mils to about 60 mils as measured from the upper surface and the lower surface of the second layer, the second layer further comprising a non-woven intermediate layer positioned between the upper surface and the lower surface of the second layer; and a bottom layer having an upper surface opposite a lower surface; wherein the upper surface of the second layer is heat-adhered to the lower surface of the first layer and the upper surface of the bottom layer is coupled to the lower surface of the first layer.

Other embodiments of the present invention include a method of forming a laminate flooring product comprising: a) providing a first layer and a second layer, the second layer comprising a non-woven material and a plastisol composition and the first layer comprising polymeric binder and plasticizer; b) positioning the first layer adjacent to the second layer; and c) heat-adhering the first layer to the second layer to form the laminate flooring product.

Other embodiments of the present invention include a laminate flooring product comprising a first layer having an upper surface opposite a lower surface and a first thickness ranging from about 70 mils to about 150 mils as measured from the upper surface to the lower surface of the first layer; and a second layer having an upper surface opposite a lower surface and a second thickness ranging from about 14 mils to about 60 mils as measured from the upper surface and the lower surface of the second layer, the second layer further comprising a non-woven intermediate layer positioned between the upper surface and the lower surface of the second layer; and wherein the upper surface of the second layer is coupled to the lower surface of the first layer; and wherein the second layer has greater flexibility than the first layer.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 illustrates an exemplary product laving a flexible layer and a rigid layer according to an embodiment of the disclosure.

FIG. 2 illustrates an exemplary product having a flexible layer and a rigid layer according to an embodiment of the disclosure.

FIG. 3 is a flow chart of an exemplary process of forming flexible according to an embodiment of the disclosure.

FIG. 4 is a flow chart of another exemplary process of forming a rigid layer for a product according to an embodiment of the disclosure.

Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.

DETAILED DESCRIPTION

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.

Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight. The amounts given are based on the active weight of the material.

Provided is a product, a melt-processed layer, a flexible layer, and a process of fabricating a product. Embodiments of the present disclosure provide dimensional stability, provide resistance to buckling, provide resistance to show-through (for example, of rigid dark colored backing), provide resistance to subfloor irregularities, provide wear resistance, reduce costs (for example, by decreasing the amount of delaminated product), provide visual quality, provide desirable installation characteristics (such as, smooth surfaces), are capable of being used in various types of products (for example, vinyl flooring laminates, installed floating floors, and/or full spread floors), and combinations thereof.

Referring to FIG. 1, in one embodiment, a product 100 includes a first layer 102 and a second layer 104 heat-adhered to the first layer 102. The heat adherence secures the first layer 102 and the second layer 104 through any suitable mechanism, such as, thermoplastic bonding, diffusion between layers catalyzed by applying heat, reaction of a heat-sensitive material between or at the abutting portion of the layers, any other suitable heat-activated adherence, or combinations thereof. In some embodiments of the disclosure, the first layer 102 and/or the second layer 104 are capable of being used in products (not shown) that are not heat-adhered. Similarly, while some embodiments of the process disclosed herein include the first layer 102 and the second layer 104 being heat-adhered, other embodiments include the first layer 102 and the second layer 104 being fabricated for such other products and/or being secured by additional or alternative mechanisms.

The product 100 includes an suitable features. For example, in one embodiment, the product 100 includes beveled or unbeveled edges that are painted or stained to provide decorative advantages. In one embodiment, the product 100 is offset-laminated to provide a shiplap joint for use in floating floor installations. In one embodiment, the product 100 includes features to provide grip or support for use in floating floor installations. In one embodiment, the product 100 is cut into planks longer than four feet, limited only by print repeat in some cases. In one embodiment, the product 100 is mechanically embossed, including embossed-in-register, prior to cutting.

The second layer 104 has greater flexibility than the first layer 102. Despite the first layer 102 and the second layer 104 having differing degrees of flexibility, the product 100 has dimensional stability. As used herein, the term “dimensional stability” refers to being substantially resistant to separation of layers, either in whole or in part, usually attributable to relative movement of such layers when one or more of the layers are subjected to a temperature above or below the temperature of one or more other layers. For example, in one embodiment, dimensional stability results in the product 100 being substantially resistant to delamination, retaining a substantially planar profile, having resistance to shrinkage in use over time, or combinations thereof. In one embodiment, the product has a predetermined dimensional stability shrinkage (amount of change of length of test piece when temperature tested), for example, between about 0.2% and about 0.3%, between about 0.1% and about 0.3%, between about 0.05% and about 0.3%, between about 0.1% and about 0.2%, between about 0,05% and about 0.1%, between about 0.04% and about 0.06%, less than about 0.3%, less than about 0.2%, less than about 0.1%, less than about 0.06%, less than about 0.05%, or any suitable combination or sub-combination thereof.

In one embodiment, the first layer 102 includes a vinyl composition. Suitable vinyl compositions include, but are not limited to, polyvinylchloride (including copolymers and/or homopolymers), luxury vinyl tile, vinyl compositions of vinyl composition tile, and vinyl compositions of vinyl asbestos tile (or products replacing asbestos). In a further embodiment, the vinyl composition includes one or more plasticizers, one or more stabilizers, one or more binders, one or more fillers, and/or one or more pigments, such as a chloride processing pigment (for example, titanium dioxide). In one embodiment, the first layer 102 includes biobased materials (for example, materials having a carbon signature identifying the materials as being from a non-synthetic source), recycled materials (for example, materials capable of being identified as being from a previously used product), renewable materials (for example, materials capable of being decomposed), or combinations thereof. To increase the flatness and rigidity of the first layer 102, in one embodiment, the vinyl composition includes a predetermined concentration of the plasticizer (for example, a relatively high concentration) and a predetermined concentration of the binder (for example, a relatively low concentration).

The predetermined concentration of the plasticizer in the vinyl composition is, by weight, between about 4% and about 10%, between about 5% and about 7%, between about 5% and about 6%, between about 6% and about 10%, between about 6% and about 7%, between about 8% and about 10%, between about 8% and about 9%, about 9%, about 8%, about 7%, about 6%, about 5%, greater than about 4%, greater than about 5%, greater than about 6%, or any suitable combination or sub-combination thereof. In one embodiment, the plasticizer includes or is a non-phthalate plasticizer.

The predetermined concentration of the binder in the vinyl composition is, by weight, between about 15% and about 1.8%, between about 1.5% and about 17.5%, between about 1.5% and about 17%, between about 15% and about 16%, between about 12% and about 17%, between about 13% and about 17%, at about 17.5%, at about 17%, at about 16%, at about 15%, or any suitable combination or sub-combination thereof. In one embodiment, the binder includes or is any suitable polymeric material.

The first layer 102 is formed by any suitable process. In one embodiment, a portion or all of the vinyl composition of the first layer 102 (for example, the resin(s), the plasticizer(s), and the filler(s)) is blended and mixed, then milled and melt-processed to form the first layer 102. The melt-processing is by calendering, extruding, continuous mixing, molding, milling, other melt-processes, or a combination thereof. In one embodiment, the first layer 102 is additionally passed through two or more rolls to achieve desired properties, such as, thickness.

In one embodiment, the first layer 102 is formed by calendering. In this embodiment, the first layer 102 is formed by forming a precursor (not shown) having a predetermined thickness (for example, between about 85 mils and about 95 mils, between about 85 mils and about 90 mils, between about 90 mils and about 95 mils, or any suitable combination or sub-combination thereof). The precursor is heated to a predetermined temperature (for example, between about 300° F. and about 400° F., between about 330° F. and about 390° F., between about 370° F. and about 390° F., between about 330° F. and about 350° F., or any suitable combination or sub-combination thereof). In one embodiment, the precursor is built up by applying more of the precursor and subsequent heating, for example, to the same temperatures or slightly higher temperatures. The precursor is then processed, for example, by pressure from a calender, to form the first layer 102. In one embodiment, the first layer 102 includes a predetermined thickness, for example, between about 40 mils and 250 mils, between about 70 mils and 250 mils, about 170 mils and 250 mils, about 70 mils and 150 mils, between about 70 mils and 160 mils, between about 40 mils and 160 mils, at least 70 mils, at least 90 mils, at least 120 mils, at least 150 mils, or any suitable combination or sub-combination thereof.

Referring again to FIG. 1, in one embodiment, the first layer 102 is secured to a bottom layer 106, for example, through lamination and/or by an adhesive. The adhesive is any suitable adhesive, for example, such as a hot melt adhesive, a pressure sensitive acrylic adhesive, or a structural and/or reactive adhesive. In one embodiment, the bottom layer 106 is a rigid black polyvinyl chloride film, but may be formed, for example, from a film or tape comprising plastic, vinyl, polyester, polyolefin, nylon, or combinations thereof. In further embodiments, the bottom layer 106 includes recycled material, such as post industrial or post consumer scrap, is rigid or flexible, is moisture resistant or waterproof, or has any other suitable properties. In one embodiment, the bottom layer 106 has a predetermined thickness, for example, between about 5 mils and about 30 mils, between about 15 mils and about 30 mils, between about 25 mils and about 30 mils, at least 5 mils, at least about 10 mils, at least about 15 mils, at least about 25 mils, or any suitable combination or sub-combination thereof.

In one embodiment, the bottom layer 106 includes multiple layers, such as two layers of film laminated with a mat, such as a glass mat or polyethylene terephthalate mat. Additionally or alternatively, in one embodiment, the bottom layer 106 includes a continuous or discontinuous ink, antimicrobial properties, sound-dampening properties, cushioning properties, slide resistant properties, stiffening properties, channeling properties, mechanically embossed texture, chemical texture, or combinations thereof. Similarly, in one embodiment, the first layer 102 includes such features and/or printed or textured portions on either surface of the first layer 102.

The second layer 104 has a predetermined thickness and is secured to the first layer 102. For example, in one embodiment, the predetermined thickness is between about 14 mils and about 60 mils, between about 20 mils and about 40 mils, less than about 60 mils, less than about 50 mils, less than about 40 mils, less than about 30 mils, less than about 25 mils, less than about 20 mils, or any suitable combination or sub-combination thereof. In one embodiment, the second layer 104 includes a non-woven layer 108, a decorative layer 110, and a wear layer 112.

The non-woven layer 108 includes a non-woven material, such as a scrim, as a base to build up the layer. In one embodiment, the non-woven layer 108 has thickness between about 10 mils and about 30 mils, between about 10 mils and about 20 mils, between about 20 mils and about 30 mils, between about 10 mils and about 15 mils, between about 15 mils and about 20 mils, or any suitable combination or sub-combination thereof. In one embodiment, the non-woven layer 108 is resistant to softening up to a predetermined temperature (for example, 420° F.). The non-woven material includes one or both of glass and polyester, which is then saturated with plastisol (a suspension of polyvinyl chloride particles in a plasticizer), for example, by being processed on large heated rolls with the plastisol coating and filling voids in a grid of the non-woven material. The plastisol further secures the second layer 104 to the first layer 102. In one embodiment, the non-woven layer 108 includes an intermediate layer (not shown) on one or both of the top and the bottom surface. The intermediate layer includes a gel coating, a tacky outer surface of the plastisol coating that is partially-cured or partially-solidified, a foam coating, or any suitable combination thereof.

In one embodiment, the decorative layer 110 includes a printable plastisol layer 114. In one embodiment, the printable plastisol layer 114 has a predetermined thickness, for example, between about 4 mils and 40 mils, between about 10 mils and about 20 mils, between about 20 mils and about 30 mils, between about 7 mils and about 11 mils, or any suitable combination or sub-combination thereof. In one embodiment, the printable plastisol layer 114 is applied as a coating to the non-woven layer 108, then a pigment or ink coating layer 116 is applied onto the printable plastisol layer 114 and/or is rendered a solid or gelled by intermediate heat treatment (for example, between about 250° F. and about 300° F.). In further embodiments, the printable plastisol layer 114 includes a white base or other pigmentation. Alternatively, the printable plastisol layer 114 includes the intermediate layer. In one embodiment, the ink coating layer 116 includes pigments or other printing on film or other suitable material applied to the printable plastisol layer 114 by, for example, rotogravure printing. In one embodiment, the ink coating layer 116 has a predetermined thickness, for example, between about 0.1 mils and about 0.5 mils, between about 0.3 mils and about 0.5 mils, between about 0.1 mils and 0.3 mils, less than 0.5 mils, or any suitable combination or sub-combination thereof.

In one embodiment, the wear layer 112 includes a plastisol clearcoat layer 118 and a coating wear layer 120. In one embodiment, the plastisol clearcoat layer 118 has a predetermined thickness, for example, between about 0.1 mils and about 40 mils, between about 10 mils and about 40 mils, between about 10 mils and about 20 mils, between about 20 mils and about 30 mils, less than about 40 mils, less than about 20 mils, or any suitable combination or sub-combination thereof. In one embodiment, the coating wear layer 120 has a predetermined thickness, for example, between about 0.1 mils and about 5 mils, between about 1 mil and about 5 mils, between about 3 mils and about 5 mils, between about 0.1 mils and about 0.5 mils, less than about 5 mils, less than about 1 mil, less than about 0.5 mils, about 0.5 mils, or any suitable combination or sub-combination thereof. The plastisol clearcoat layer 118 is applied to the ink layer 116. After the plastisol clearcoat layer 118 is allowed to cool and expand, the coating wear layer 120 is applied onto it. The coating wear layer 120 is a polymeric film, such as a radiation-curable coating, a thermally-curable coating, or other suitable material. The coating is radiation-cured, for example, by use of electron beam or ultra-violet light, or combination thereof. In one embodiment, after the coating wear layer 120 is applied and cured, the product 100 is further cooled, and then press diecut into planks, tiles, or any other suitable product.

Referring to FIG. 2, in one embodiment, a product 200 similar to the product 100 of FIG. 1 includes the first layer 102 and a second layer 204 heat-adhered to the first layer 102. In one embodiment, the second layer 204 includes the non-woven layer 108, the decorative layer 110, a protective layer 206, and a wear layer 208. The protective layer 206 includes a plastisol clearcoat layer 210 applied to the ink coating layer 116, with a coating wear layer 212 applied on the plastisol clearcoat layer 210 (the coating wear layer 212 having been applied after the plastisol clearcoat layer 210 was allowed to cool and expand). In one embodiment, the plastisol clearcoat layer 210 includes the intermediate layer (not shown) on one or both of the top and the bottom surface. In one embodiment, decorative layer 110 is devoid of the pigment or ink coating layer 116, and additionally or alternatively, a clear film 214 includes printing.

In one embodiment, the coating wear layer 212 is a radiation-curable coating. The coating wear layer 212 includes the clear film 214 and a surface coating 216. The surface coating 216 is a radiation-curable coating or other suitable material. In one embodiment, after the surface coating 216 is applied and cured, the product 200 is further cooled, and then press diecut into planks or tiles or any other suitable product.

Referring to FIG. 3, in one embodiment, a process 300 of fabricating a product (for example, the product 100 of FIG. 1 or the product 200 of FIG. 2) or a portion of the product (for example, the second layer 104) includes preparing the non-woven material (step 302), for example, by unwinding a flexible roll of the non-woven material. The process 300 then includes saturating the non-woven material to form the non-woven layer step 304), for example, by rendering it a solid or gelling with plastisol. Next, the process 300 includes forming the intermediate layer on or in the non-woven layer (step 306) and applying and curing one or more of the coatings and/or layers described above (step 308), thereby forming the second layer (step 310). In a further embodiment, the process 300 includes positioning the second layer on the first layer (step 312) and heat adhering the second layer to the first layer (step 314) to form the product. As will be appreciated, the process 300 includes any other suitable steps for forming the features described above.

Referring to FIG. 4, in one embodiment, a process 400 of fabricating a product (for example, the product 100 of FIG. 1 or the product 200 of FIG. 2) or a portion of the product (for example, the first layer 104) includes blending, milling, and/or melt-processing a composition (for example, the vinyl composition) to form the first layer (step 402). The process 400 continues by heating the first layer (step 404). In a further embodiment, the process 400 further includes positioning the first layer to receive the second layer (step 404) and heat adhering the second layer to the first layer (step 406). As will be appreciated, the process 400 includes any other suitable steps for forming the features described above. In one embodiment, the process 400 described with reference to FIG. 4 and the process 300 described with reference to FIG. 3 are combined to form the product 100 having the first layer 102 and the second layer 104.

While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. 

What is claimed is:
 1. A laminate flooring product comprising: a first layer having an upper surface opposite a lower surface and a first thickness ranging from about 70 mils to about 150 mils as measured from the upper surface to the lower surface of the first layer; and a second layer having an upper surface opposite a lower surface and a second thickness ranging from about 14 mils to about 60 mils as measured from the upper surface and the lower surface of the second layer, the second layer further comprising a non-woven intermediate layer positioned between the upper surface and the lower surface of the second layer; and a bottom layer having an upper surface opposite a lower surface; wherein the upper surface of the second layer is heat-adhered to the lower surface of the first layer and the upper surface of the bottom layer is coupled to the lower surface of the first layer.
 2. The laminate flooring product of claim 1, wherein the first layer further comprises a polymeric binder and plasticizer.
 3. The laminate flooring product of claim 2, wherein the plasticizer is present in a maximum amount of about 10 wt. % based on the total weight of the first layer.
 4. The laminate flooring product of claim 2, wherein the polymeric binder is present in a maximum amount of about 18 wt. % based on the total weight of the first layer.
 5. The laminate flooring product of claim 1, wherein the second layer further comprises a plastisol composition and the non-woven intermediate layer is impregnated with the plastisol composition.
 6. The laminate flooring product of claim 1, wherein the second layer further comprises a decorative sub-layer comprising ink, wherein the decorative sub-layer is positioned between the upper surface and the lower surface of the first layer.
 7. The laminate flooring product of claim 1, wherein the second layer has greater flexibility than the first layer.
 8. The laminate flooring product of claim 1, wherein the laminate flooring product further comprises a first major surface opposite a second major surface and the first major surface comprises the upper surface of the second layer and the second major surface comprises the lower surface of the bottom layer.
 9. The laminate flooring product of claim 1, wherein the bottom layer has a third thickness ranging from about 5 mils to about 30 mils as measured from the upper surface to the lower surface of the bottom layer.
 10. The laminate flooring product of claim 1, wherein the bottom layer is a film formed from at least one of vinyl polymer, polyester, polyolefin, nylon, and combinations thereof.
 11. The laminate flooring product of claim 1, wherein the non-woven intermediate layer non-woven layer includes one or both of glass and polyester.
 12. A method of forming a laminate flooring product comprising: a) providing a first layer and a second layer, the second layer comprising a non-woven material and a plastisol composition and the first layer comprising polymeric binder and plasticizer; b) positioning the first layer adjacent to the second layer; and c) heat-adhering the first layer to the second layer to form the laminate flooring product.
 13. The method of claim 12, wherein the second layer is formed by impregnated the non-woven material with the plastisol composition and gelling the plastisol composition at an elevated temperature.
 14. The method of claim 13, wherein the elevated temperature ranges from about 250° F. to about 300° F.
 15. The method of claim 12, wherein the first layer is formed by creating a mixture of the polymeric binder and plasticizer and calendering the mixture between at least two heated rolls to form the first layer.
 16. The method of claim 12, wherein the first layer of step a) has a thickness ranging from about 70 mils to about 150 mils.
 17. The method of claim 12, wherein the second layer of step a) has a thickness ranging from about 14 mils to about 60 mils.
 18. A laminate flooring product comprising: a first layer having an upper surface opposite a lower surface and a first thickness ranging from about 70 mils to about 150 mils as measured from the upper surface to the lower surface of the first layer; and a second layer having an upper surface opposite a lower surface and a second thickness ranging from about 14 mils to about 60 mils as measured from the upper surface and the lower surface of the second layer, the second layer further comprising a non-woven intermediate layer positioned between the upper surface and the lower surface of the second layer; and wherein the upper surface of the second layer is coupled to the lower surface of the first layer; and wherein the second layer has greater flexibility than the first layer.
 19. The laminate flooring product of claim 18, wherein the first layer further comprises a first sub-layer, the first sub-layer being a wear layer, wherein the first sub-layer is positioned between the upper surface and the lower surface of the first layer.
 20. The laminate flooring product of claim 18, wherein the first layer if formed from a radiation curable composition. 